Screw weight saving....just add more HP (Project Turbo Smurf)

[Tuna]

Re: Screw weight saving....just add more HP (Project Turbo Smurf)

I would still like to come by and check it out/help out when you resume.

I would probably never have the nerve but someday I'd like to swap everything out of the Jetta and put it into a mk3 4-door or cabrio or something. Looks like it shouldn't take you too long to have that thing up and running!

[RONDAL]

Re: Screw weight saving....just add more HP (Project Turbo Smurf)

we're gonna be working on getting it into the stand and i would like to start taking apart the head as well.
you're welcome to come round, gimme a call around lunch time and i can let you know whats going on
870-4986

[RONDAL]

Re: Screw weight saving....just add more HP (Project Turbo Smurf)

I would still like to come by and check it out/help out when you resume.

I would probably never have the nerve but someday I'd like to swap everything out of the Jetta and put it into a mk3 4-door or cabrio or something. Looks like it shouldn't take you too long to have that thing up and running!

i could help you swap if you wanted down the road. after doing this myself it is a lot less complicated than i thought it was. once you know where everything goes and what it all looks like once apart it really makes it less scary.

[RONDAL]

Re: Screw weight saving....just add more HP (Project Turbo Smurf)

PEEK A BOO!







also got to changing the mounts out.

front one and tranny were easy, can't figure out how to take apart the lower cup on the side mount however. Screwdriver and pry the clips upwards??

[DeanerF]

Re: Screw weight saving....just add more HP (Project Turbo Smurf)

lookin good andrew!

I'm thinking that I might take mine out this winter too.. to clean up the bay etc.

what are you all doing to the head?

[RONDAL]

Re: Screw weight saving....just add more HP (Project Turbo Smurf)

headspacer and timing chains

[edicius]

Re: Screw weight saving....just add more HP (Project Turbo Smurf)

Is the headspacer to lower compression?

[Triple G]

Re: Screw weight saving....just add more HP (Project Turbo Smurf)

Yes

[RONDAL]

Re: Screw weight saving....just add more HP (Project Turbo Smurf)

December 9, 2007

Went and got drunk last night at the company christmas party so I spent the morning on the couch watching football and the Patriots winning another one before heading down to the garage.
Once I finally got my ass motivated I was able to get a bunch of stuff done. Graeme came over again half way through to drop off the 27mm socket I needed and help read instructions from my timing chain guide I put together.


Started where I left off earlier in the week and pried apart the side mount lower cup from the top cup using a set of pliers to pull the 4 metal clips back slightly.







Once apart I gained access to the lower part of the stock mount which was super squishy and gross.







Assembled the mount back together with the new BFI Stage1 mount inserts.





Here you can see the comparison between the old tranny mount and the new BFI Stage1 tranny mount that I also swapped in.









Then i went back to the engine and began working on getting it all apart.

Pulled out the spark plugs using a 5/8" deep socket.




Then using my trusty M80 bolt I keep in my ashtray for this specific reason I loosened off my serpentine belt tensioner. This would allow me enough slack to remove the belt itself off. I will be changing the belt as well, I changed it when i first got the car at 108,000km's and figure it wouldn't hurt to replace it again.









When I pulled the valve cover off I found that my camshafts were in this position.





I needed to rotate them so that cylinder #1 was in TDC position. THis would make the grooves in both cam shafts be horizontal and parallel to the top of the head allowing me to slide the VW camshaft plate into place to stop the cams spinning changing the timing during the timing chain replacement steps.
To spin the camshafts I spun the 27mm bolt on the bottom of the block CLOCKWISE until the cams were in proper position. dont spin it counter clockwise if you try doing this, apparently its bad for the engine.




Once the cams grooves were parallel with the top of the head I inserted the cam locking plate, undid the 27mm bolt on the back of the head and the 5mm allen bolts on the timing chain cover. I was then able to remove the top half of the timing chain cover.




Then went about undoing all of the 10mm bolts on the lower timing chain cover as well as the 3 5mm allen bolts on the bottom which also hold the oil pan on.




Once this was done I was able to remove the lower cover exposing the timing chain setup.






I then undid the 2 13mm bolts holding the upper rail guide on.





I then slide the guide upwards and out below the chain and out of the engine. Below you can see the state of the guides, they were actually in very good condition with very minimal grooving if any. You couldn't catch your nail on them even.




I then slackend the chains by undoing the intermediate sprocket (15mm), it was a ***** to undo but nothing that my massive breaker bar couldn't handle.




Once loose I then removed the intermediate sprocket and along with it the upper timing chain.






Once the chain is removed the upper tensioner rail falls down from where it was through the hole in the exposed headgasket. It is simply held on with a pin so you can then just pull it right off.






As you can see again, very little wear on the tensioner itself.




I then removed the lower tensioner and the lower rail body with the 2 5mm allen bolts that hold each on.






Again, very little wear on the contact parts.






Pulled off the inner intermediate sprocket and along with it the lower timing chain.





At this point all of the timing chain parts are now removed from the engine.






Began to pull the head apart physically. Removed the god knows how many head bolts.








All the bolts are removed, you can also see clearly the VW cam locking plate in place stopping the cams from moving at all.







Then we pried the head off of the block and seperated the gasket. The oil you see simply leaked down from the head as we removed it, there was no leak in the headgasket or anything prior to doing this work.








Put the head on some cardboard and old soft t-shirts.










That's all for today. Later in the week or next weekend I will try and clean up the pistons with some brake cleaner, I have rags on the block soaking up any of the excess oil that spilled.

Next will be installing the headspacer and new headgasket as well as re-assembling the timing chain setup with the new hardware. I have all new guides, tensioners and chains to go onto the engine. Will also install the phelonic spacer while the head is off of the block and I have easy access to all the bolts.

[R_Ethug]

Re: Screw weight saving....just add more HP (Project Turbo Smurf)

awesome!

[edicius]

Re: Screw weight saving....just add more HP (Project Turbo Smurf)

are you checking your block for flatness while its off?

[RONDAL]

Re: Screw weight saving....just add more HP (Project Turbo Smurf)

i think im going to yea. I am actually researching that right now

[MischlingMk]

Re: Screw weight saving....just add more HP (Project Turbo Smurf)

just signed onto the forum. this is a SICK build. i am impressed to see you doing this yourself too. respect that. will be following this one for sure. how big of a head-spacer you putting on (mm's)? is that stock timing chain gonna be strong enough?

[RONDAL]

Re: Screw weight saving....just add more HP (Project Turbo Smurf)

headspacer is 4.15mm thick just measured it with digi cal.

stock timing chainS are more than ample. I have never even heard of one of them breaking.

[RONDAL]

Re: Screw weight saving....just add more HP (Project Turbo Smurf)

Dec 9, 2007:

New toys arrived today and yesterday.

ARP Headstuds for bolting the head and block back together from Mopac.





Big Finger to UPS for screwing us Canadians on their damn brokerage fees. I had to use air mail to get these gears up costing me a fortune to avoid massive amounts of fees for them to bring them across the border. So much for NAFTA.






The gears.